Methods for manufacturing a radio frequency identification tag without aligning the chip and antenna

ABSTRACT

A method for attaching antennae to RFID tags is disclosed. Included is the use of RFID tags having asymmetrical interconnect system for one or more antennae, such that virtually any rotational orientation of the RFID tag will result in a successful antennae attachment. Two oversized and “L” shaped gold-bumped holes can be arranged on the same side of the ship in an opposing action, such that at least one axis of symmetry is formed. Accordingly, virtually all rotational orientations of the chip are then acceptable when attaching a pair of opposing pole antenna leads. Alternatively, a pair of poles can be located on opposing chips surfaces, such that antenna substrates can be attached to both the top and bottom of the chip to form a product “sandwich”, whereby the rotational orientation of the chip is irrelevant at an antenna attachment step.

PRIORITY CLAIM

This application is a divisional application of and claims priority tocommonly owned U.S. patent application Ser. No. 10/651,683, filed Aug.29, 2003 (now U.S. Pat. No. 7,230,580, issued Jun. 12, 2007), which isincorporated herein in its entirety and for all purposes.

TECHNICAL FIELD

The present invention relates generally to an apparatus and method forconnecting components to an integrated circuit device, and morespecifically to an apparatus and method for attaching RFIDICs toantennae.

BACKGROUND

Radio Frequency Identification (“RFID”) tags and systems have beenwidely adopted in recent years for the traceability and tracking of awide variety of products and objects. Although these wireless systemsare similar to UPC bar code type systems in that they allow for thenon-contact reading of various products, items and devices, they are aneffective improvement over UPC bar code systems in a variety of ways. Infact, RFID tags and systems can be vastly superior to bar code systemsin many manufacturing and other hostile environments where bar codelabels are inconvenient or wholly impractical. A significant advantageof RFID tags and systems is the non-line-of-sight nature of thetechnology, whereby tags can be read through a variety of substancessuch as snow, fog, clothing, paint, packaging materials or othervisually challenging conditions where UPC bar codes or other opticallyread technologies would be useless.

Another advantage is that RFID tags can also be read at relatively highspeeds, frequently in less than 100 milliseconds per tag, which canresult in the ability of an RFID system to read hundreds of tags persecond when combined with the non-line-of-sight nature of thetechnology. The read/write capability of an active RFID system can alsobe a significant advantage in applications where changes in the data forindividual items is desired, such as work-in-process or maintenancetracking. In addition, most RFID tags comprise a user-programmable codethat is typically 32 to 128 bits, whereby RFID tags can record much moreinformation than a standard bar code, including items such as, forexample, a unique identification code, where a device was manufactured,where it was sold, and who purchased the device.

RFID tags come in a wide variety of shapes and sizes, and are usuallynoted for their particularly small and unobtrusive nature. Large RFIDtags include, for example, the hard plastic anti-theft devices attachedto merchandise in stores, credit-card shaped tags for use in accessapplications, and screw shaped tags for use with trees or wooden items.In smaller versions, animal tracking tags inserted beneath the skin canbe as small as a pencil lead in diameter and one-half inch in length.Tiny RFID tags can be even of a size on the order of a flat squaremeasuring about 500 microns per side (i.e., the size of a flake ofpepper), although tags this small typically require an antenna of atleast a half an inch to four inches or more, depending on theapplication. Applications and venues utilizing some form of RFID tagsand systems vary dramatically and can include, for example, packagedelivery, luggage handling, highway toll monitoring, livestockidentification, and automated vehicle identification systems, amongothers. In addition, RFID tags can be implemented in a wide variety ofgeneral product inventory and tracking applications that range fromwashable RFID tags designed to be sewn into clothing to speciallydesigned RFID tags and antennae for automobile tires. Even the Europeancentral bank is considering embedding tiny RFID tags into banknotes by2005.

In most applications, an ordinary RFID system comprises essentiallythree primary components: 1) one or more transceivers for transmittingand receiving radio frequency signals, 2) at least one transponderelectronically programmed with data, preferably comprising uniqueinformation, and 3) at least one antenna. The transceiver is generallyanalogous to a bar code scanner, and controls communication within thesystem by restricting when and where data is written, stored andacquired. The transponder is generally analogous to a bar code label,and typically comprises at least a small chip containing an integratedcircuit, with this chip often being referred to as an RFID IntegratedCircuit (“RFIDIC”). Antennae are essentially the conduits betweenRFIDICs and transceivers, as RFIDICs are frequently too small to act astheir own antennae and collect a sufficient level of emitted radiosignals standing alone. Antennae can be attached to the transceiver, thetransponder, or both, and are generally used to emit and/or collectradio signals to activate an RFIDIC, read data from the RFIDIC and/orwrite data to it.

In general, the term “RFID tag” refers to the combination of the RFIDICand the antennae attached thereto. An RFID tag is essentially aminiscule microchip, with attached antennae, that listens for a radioquery and responds by transmitting an identification code that isfrequently unique to that RFID tag. In operation, the transceivergenerally emits radio waves in ranges of anywhere from a fraction of aninch to 100 feet or more, depending upon the power output and radiofrequency utilized. When an individual RFID tag passes through anelectromagnetic zone covered by the transceiver, it detects theactivation signal of the transceiver and responds by emitting itsindividual recorded code. The “reader” or transceiver then collects thisemitted code and passes this data along to a host computer or other likedevice for processing.

RFID tags are typically categorized as either active or passive. ActiveRFID tags are usually powered by an internal battery, can potentiallyeven include a mini-processor, and can advantageously have read/writecapabilities. Such active tags, however, tend to be relatively large andcostly and tend to have a limited operational life. Conversely, passiveRFID tags operate without a separate external power source, as powersufficient to operate a passive RFID tag is actually generated from theradio waves emitted by the transceiver. Although such passive tagsgenerally cannot comprise a mini-processor or have read-writecapabilities, they tend to be smaller, lighter and less expensive thanactive tags, and have a potentially infinite operational life. Suchpassive or “read-only” type tags are typically “write-once” type ofintegrated circuits, programmed with a unique set of data that cannot bemodified, and essentially operate as a static data entry into adatabase, similar to the way that UPC bar codes are used. Due in part tothe relative simplicity and lower costs, the majority of actual RFIDtags fall into the “passive” category.

A wide variety of antenna materials and types are possible for RFIDtags, and such antenna materials can include thin strips or traces ofmetal or other conducting material fabricated onto a specificallydesigned substrate or other medium. Such a medium can be speciallyprovided, or actually built into the product containing the RFID tag. Inone example, the military is working with RFID designs where theantennae are conducting threads built into the clothing of personnel tobe tracked in the field. Standard apparatuses and methods formanufacturing RFID tags are well known, and instances of suchapparatuses and methods can be found, for example, in U.S. Pat. Nos.6,100,804 and 6,509,217, both of which are incorporated herein byreference in their entirety.

A major barrier to the broad adoption of tiny RFID tags and similarlyadvanced technologies in the thin-margin businesses of retail sales andconsumer commodities has been the high cost of the equipment. For thetags alone, many manufacturers can expect to pay a relatively premiumprice per tag in low quantities. In quantities of about 1 billion,however, costs for RFID tags can drop significantly, and in lots of 10billion or more, further reduced costs permitting for widespreadadoption of the tags are hoped to be possible. In order for such lowcosts to be realized, however, it is generally accepted within theindustry that significant improvements to and streamlining of themanufacturing process of such tags will be needed. One area whereimprovements may be possible is in the design and attachment of antennaeto the RFID tag.

A typical passive RFID tag comprises a two pole RFIDIC connected to anantenna that is fabricated onto a substrate. Alternatively, a passiveRFID tag can comprise a four pole RFIDIC with at least one and usuallytwo of the poles connected to an antenna. Additional poles can either be“dummy” poles that do nothing, or can be used in conjunction with abattery or external power source, in the case of active or otherwisepowered RFID tags. A wide variety of apparatuses and techniques existfor providing poles on RFIDICs to which antennae can be attached, withone example being gold bumps formed on an “active” side of the chip,such methods as will be readily known and understood by those skilled inthe art. Advantages of techniques such as the formation of gold bumps toattach antennae include higher throughput, lower assembly costs, and theease of accommodation with respect to differing sizes and shapes ofRFIDICs and antennae.

Disadvantages of such techniques, however, tend to include thenecessitated use of individual pick and place methods for orienting eachRFIDIC during manufacture, such as before attaching each antenna to eachRFIDIC. That is, the manufacture of RFID tags typically requires thatany particular RFIDIC be oriented in a particular position before theantenna or antennae can be attached to the tag in an operable manner.Such specific orientation requirements result in the need forindividualized handling of each RFIDIC to some degree, such thatstandard pick and place robotics or similar apparatuses or techniquesare popularly used during the manufacturing process. The use ofindividual pick and place manufacturing devices and techniques, however,tends to result in a significantly slower and costlier manufacturingprocess, and precludes the use of many more favorable alternative bulkmanufacturing methods and techniques.

Accordingly, there exists a need for improved apparatuses and methodsfor attaching antennae to RFIDICs that permits the use of more favorablebulk manufacturing methods and techniques, and specifically a need forimproved RFIDIC designs and manufacturing techniques such thatindividualized pick and place devices and methods are minimized oreliminated.

SUMMARY

It is an advantage of the present invention to provide an apparatus andmethod for attaching antennae to RFID chips. According to one embodimentof the present invention, the provided apparatus comprises an RFID chipor RFIDIC having a symmetrical interconnect system for attaching one ormore antennae, such that virtually any rotational orientation of theRFIDIC will still result in a successful attachment of the antennaethereto. Under such an embodiment, an appropriate method ofimplementation would include the steps of selecting a first RFIDIC,creating a plurality of antenna pole attachments on such an RFIDIC,utilizing a mass parts handling system to process the RFIDIC, andcoupling a plurality of antenna leads to one or more of said antennapole attachments.

Accordingly, the current invention specifies a pole arrangement and chipinterconnect design by which an antenna attachment process can beaccomplished independent of the rotational orientation of the chip(i.e., RFIDIC). One specific embodiment for accomplishing such a resultinvolves the use of two oversized and “L” shaped poles, which arearranged on the same side of a chip in an opposing fashion, such that atleast one axis of symmetry is formed. Under such an arrangement,virtually any rotational orientation of the chip will result in anacceptable orientation for connecting a pair of opposing antenna leads.

In an alternative embodiment of the present invention at least eightpoles are used, with four poles designated for use with antenna leads,and four other poles designated for use with power or ground leads. Thearrangement of these eight leads is such that at least one axis ofsymmetry is formed across the face of the RFIDIC, with one example beingthat all four of one type of pole are in the corners, while all four orthe other type of pole are at the midpoint of each edge of the RFIDIC.Under such a symmetrical arrangement, at least four different rotationalorientations of the chip will result in an acceptable orientation forconnecting a pair of opposing antenna leads and a ground lead to thepoles.

In yet another embodiment of the present invention a pair of poles isagain used, only with the two connections on the RFIDIC being located onopposing chip surfaces. The connections to an antenna substrate can thenbe achieved by either using a flexible contact that was part of a chipcarrier or by positioning the chip between two halves of an antennawherein both sides of the chip are simultaneously attached to it. Such aresult is possible through the use of, for example, a pair ofcontinuously supplied antenna substrates onto which individualbulk-processed RFIDICs are fed, thereby forming a product “sandwich” ofan RFIDIC between two antenna substrates.

As disclosed, the present invention allows for significantly higherthroughput due to a total forgiveness of chip orientation in theassembly and manufacturing process, which is in turn a result of thesymmetrical or otherwise strategically manipulative design of the polearrangement and chip circuitry. Such higher throughput inevitablyresults in reduced costs, and in the present case, costs that aresignificantly reduced beyond any incremental costs increases required toimplement the improved inventive chip and pole designs.

Other apparatuses, methods, features and advantages of the inventionwill be or will become apparent to one with skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description, be within the scope ofthe invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The included drawings are for illustrative purposes and serve only toprovide examples of possible structures for the disclosed inventiveapparatus and method for attaching antennae to RFID chips. Thesedrawings in no way limit any changes in form and detail that may be madeto the invention by one skilled in the art without departing from thespirit and scope of the invention.

FIG. 1 illustrates in top plan view an exemplary RFID tag having aparticular pole and antenna arrangement.

FIG. 2 illustrates in top plan view another exemplary RFID tag having analternative antenna arrangement.

FIG. 3 illustrates in top plan view an exemplary RFIDIC having analternative pole arrangement according to one embodiment of the presentinvention.

FIG. 4 illustrates in side elevation view the RFIDIC of FIG. 3 accordingto one embodiment of the present invention.

FIG. 5 illustrates in top plan view the RFIDIC of FIG. 3 having aparticular antenna arrangement attached to form an RFID tag according toone embodiment of the present invention.

FIG. 6 illustrates in top plan view another exemplary RFIDIC having analternative pole arrangement according to one embodiment of the presentinvention.

FIG. 7 illustrates in side elevation view the RFIDIC of FIG. 6 accordingto one embodiment of the present invention.

FIG. 8 illustrates in top plan view the RFIDIC of FIG. 6 having aparticular antenna and ground lead arrangement attached to form an RFIDtag according to one embodiment of the present invention.

FIGS. 9 a and 9 b illustrate in front and back perspective views yetanother exemplary RFIDIC having an alternative pole arrangementaccording to another embodiment of the present invention.

FIG. 10 illustrates in top plan view an exemplary chip arrangement usedin the manufacture of RFIDICs according to one embodiment of the presentinvention.

FIG. 11 illustrates in top perspective view an exemplary bulk-processingdevice for manufacturing RFID tags according to one embodiment of thepresent invention.

FIG. 12 illustrates in side view another exemplary bulk-processingdevice for manufacturing RFID tags according to another embodiment ofthe present invention.

DETAILED DESCRIPTION

Exemplary applications of apparatuses and methods according to thepresent invention are described in this section. These examples arebeing provided solely to add context and aid in the understanding of theinvention. It will thus be apparent to one skilled in the art that thepresent invention may be practiced without some or all of these specificdetails. In other instances, well known process steps have not beendescribed in detail in order to avoid unnecessarily obscuring thepresent invention. Other applications are possible, such that thefollowing examples should not be taken as limiting.

In the following detailed description, references are made to theaccompanying drawings, which form a part of the description and in whichare shown, by way of illustration, specific embodiments of the presentinvention. Although these embodiments are described in sufficient detailto enable one skilled in the art to practice the invention, it isunderstood that these examples are not limiting; such that otherembodiments may be used, and changes may be made without departing fromthe spirit and scope of the invention.

One advantage of the present invention is the elimination or reductionof the need for individualized pick and place devices and methods duringthe manufacturing of RFID tags. This advantage is accomplished at leastin part via the improved design of the RFIDIC, and specifically the poleor antenna contact design on the RFIDIC, such that the need for a moreprecise orientation of the RFIDIC before attaching the antenna isminimized or eliminated.

Another advantage of the present invention is the inherent increase inmanufacturing efficiency resulting from this elimination or reduction ofthe need for individualized pick and place devices and methods duringthe manufacturing of RFID tags. Such an advantage is realized where moreefficient bulk processing devices and techniques are implemented inplace of less efficient pick and place devices and techniques forhandling and processing items during the manufacturing process.

Turning now to FIG. 1, an exemplary RFID tag having a particular poleand antenna arrangement is illustrated in top plan view. It will bereadily appreciated that various independent components within FIG. 1are not necessarily to scale, especially with regard to the size andorientation of the antenna 17 with respect to the RFID tag 10. RFID tag10 comprises an RFIDIC 11 and attached substrate or backing 12. RFIDIC11 comprises four poles 13-16, which may be standard gold bumpattachment type poles, for example, although other amounts and types ofpoles are also possible. Poles 13 and 14 can be dummy poles, batteryadapted poles, or other use poles, while poles 15 and 16 are adapted foruse with a looped antenna 17. Such adaptation would include theunderlying circuitry connected to poles 15 and 16 being configured suchthat radio signals are to be received and input into the RFIDIC throughthose poles, as will be readily understood by those skilled in the art.Antenna 17 can comprise one or more metallic or otherwise conductingtraces formed onto substrate or backing 12.

Due to its particular configuration, RFIDIC 11 must be oriented into aparticular position before antenna 17 can be attached. If, for example,RFIDIC 11 is oriented 90, 180, or 270 degrees clockwise, this chip mightappear to be oriented properly, but each of poles 13-16 would be in anincorrect position if the antenna 17 were to be attached ordinarily atthe far right poles. Accordingly, the proper orientation of RFIDIC 11must be accounted for, typically via individualized pick and placedevices and methods, at least prior to the step of attaching the antennaand/or any other pole-attached components.

Referring now to FIG. 2, another exemplary RFID tag having analternative antenna arrangement is illustrated in top plan view. Similarto RFID tag 10 discussed above, RFID tag 20 comprises an RFIDIC 21 andan attached substrate or backing 22. RFIDIC 21 similarly comprises fourpoles 23-26, which may be standard gold bump attachment type poles, forexample, although other amounts and types of poles are also possible.Poles 23 and 26 can be dummy poles, battery adapted poles, or other usepoles, while poles 24 and 25 are adapted for use with a pair of opposingantenna traces 27 and 28, with such adaptation again including theproper underlying RFIDIC circuitry being connected to poles 24 and 25.Antenna traces 27 and 28 can comprise one or more metallic or otherwiseradio signal conducting traces formed onto substrate or backing 22 oronto an alternatively provided antenna support substrate or structure(not shown). If desired, substrate or backing 22 and antenna traces 27and 28 can also be of much greater size than that which is illustrated,as will be readily understood by those skilled in the art.

Again, due to its particular configuration, RFIDIC 21 must be orientedinto a particular position before antenna traces 27 and 28 can beattached to poles 24 and 25. If, for example, RFIDIC 21 is oriented 90or 270 degrees clockwise, this chip might appear to be orientedproperly, but each of poles 23-26 would be in an incorrect position ifthe antenna traces 27 and 28 were to be attached at poles ordinarilydesignated to be at the upper right and bottom left corners. RFID tag 20will also typically operate in cases where RFIDIC 21 was rotated 180degrees at the time of antenna attachment, such that antenna trace 27was attached at pole 24 and antenna trace 28 was attached at pole 25.Depending upon the design of the chip circuitry, antenna polarity, andfield signal placement, such a resulting operation will typically benormal and correct, especially for instances where a simple looped typeantenna arrangement is used, or might also result in the emission of anincorrect data bit stream that could appear normal. Of course, such areversed antenna attachment can be readily designed for via various poleand chip design techniques known in the art, such that an RFIDIC canoperate under a reversed antenna attachment just as well as under theregular antenna attachment. Still, the orientation of the RFIDIC 21would be improper in two of four potential positions in such instances,such that a proper orientation must still likely be accounted for duringthe manufacturing process.

Accordingly, one potential solution is to design RFIDIC 21 such that itsshape is substantially rectangular but not square. In this manner, ifthe length of RFIDIC 21 were extended but the breadth were to remain thesame, either orientation of the RFIDIC along a longer side (i.e., either0 or 180 degrees) would result in antenna traces 27 and 28 beingattached to poles 24 and 25. Assuming that the chip and pole designs andfield signal placements are sufficiently adequate such that eitherattachment result is valid, and that the orientation of other poles isnot critical, some bulk processing and sorting devices and methods, asdescribed in greater detail below, might be then used to process suchrectangular yet not square RFIDICs. Of course, the only such bulkprocessing devices and method that could be used would be those thatcould manage bulk or batch processed RFIDICs en masse and produce themin an orientation such that the longer sides of each RFIDIC are alignedin a given direction. While such a design may be advantageous in someways, there are several drawbacks in a rectangular yet not square RFIDICdesign that leave better designs to be desired.

Turning now to FIGS. 3 and 4, an exemplary RFIDIC having an alternativepole arrangement according to one embodiment of the present invention isillustrated in top plan and side elevation views. RFIDIC 101 ispreferably accompanied by an attached substrate or backing (not shown),as will readily understood by those skilled in the art, although such anattached substrate or backing is not absolutely necessary. RFIDIC 101comprises two poles 103 and 104, which are preferably oversized goldbump attachment type poles, although other amounts and types of polesare also possible. Other poles, which are not shown here, can includedummy poles, battery adapted poles, or other use poles, and may belocated on the same surface as poles 103 and 104, or elsewhere on theRFIDIC 101. As in the foregoing examples, poles 103 and 104 are adaptedto be attached to one or more antenna leads, with such adaptationsincluding the underlying chip circuitry connected to the poles beingconfigured such that radio signals are to be received into and emittedfrom the RFIDIC through these poles, as will be readily understood bythose skilled in the art.

As can be seen in FIG. 3, antenna poles 103 and 104 are formed along andnear the edges of RFIDIC 101, and each is substantially “L” shaped innature. In addition, it can be seen that the arrangement of antennapoles 103 and 104 is substantially symmetrical about at least one axisacross the face of RFIDIC 101, such as, for example, diagonal axis 105.While such a pole formation may require the creation of larger thannormal gold bump contacts, this arrangement of poles is instrumental inpermitting a virtually infinite number of possible rotationalorientations of the RFIDIC at the antenna attachment stage. In thetypical instance of a simple RFID tag having a two-connection loopedtype antenna and capable of operating under both a normal and reversedattachment of the two antenna leads, virtually any rotationalorientation of RFIDIC 101, with the exception of an orientation directlyalong symmetrical axis 105, will result in the correct placement ofantenna leads at the time such leads are attached to poles 103 and 104.

Referring now to FIG. 5, the RFIDIC of FIG. 3 further comprisingantennae attached in one particular arrangement to form an RFID tagaccording to one embodiment of the present invention is illustrated intop plan view. RFID tag 100 comprises the RFIDIC 101 illustrated inFIGS. 3 and 4, but now has the contact ends of two antennae leads 110attached to poles 103 and 104. In this illustrative example, it shouldbe noted that the automated devices and methods used in themanufacturing process will attempt to attach opposing antennae leads 110in the exact position and orientation as shown regardless of theposition and orientation of an underlying RFIDIC being processed. As canbe seen from FIGS. 3 and 5, however, any processed RFIDIC having any“squared” rotational orientation (i.e., 0, 90, 180 or 270 degrees from“normal”) will still result in one antenna lead 110 being attached asdesigned to pole 103 and the other antenna lead 110 being attached asdesigned to pole 104, such that the entire RFID tag will operatenormally.

Furthermore, any slight rotation of RFIDIC 101 from any of the fourperfectly squared rotational orientations will result in slightly skewedrotational orientation whereby the normal attachment of antenna leads110 will still result in a fully operable and functional RFID tag. Infact, due to the oversized nature and symmetrical arrangement of the twopoles, even substantial rotations of the RFIDIC away from a squaredrotational orientation will still result in a fully operable andfunctional RFID tag after a normal attachment of the two antenna leads.As shown in the pole arrangement of FIGS. 3 and 5, the only instancewhere a potential rotational orientation would possibly not work wouldbe where diagonal axis 105 is aligned dead-on with the opposing antennaleads 110.

The existence of such an instance might be corrected by, for example,extending the gold bump or other connector of each pole further, orthrough the incorporation of a different symmetrical pole design andarrangement, which other types of similarly manipulative pole designsand arrangements, both symmetrical and asymmetrical, are alsocontemplated. Alternatively, it is thought that if RFIDIC orientationsare truly random in a given handling process, that the relatively smallnumber of RFIDICs that would be so affected by such a dead-on rotationalorientation at the time of antennae attachment would merely constitutesome portion of the number of defective products that are inherent tomost manufacturing processes. Such manufacturing defects wouldordinarily be caught and removed for scrap or recycling purposes at oneor more various quality checkpoints at a later point in the process, andthe relatively small costs incurred by such a small percentage ofdefects will be more than recovered through the increased advantages ofbeing able to use better bulk processing devices and methods.

As a result of the symmetrical and oversized pole design and arrangementillustrated here, the automated processing of RFIDICs and attachment ofantennae thereto can take place under virtually any rotationalorientation of the RFIDIC at the time of antennae attachment (outside a“dead-on” orientation along an axis where zero or multiple contacts arepossible). Such a result paves the way for the reduction or eliminationof pick and place mechanisms and techniques, as bulk feeders andhandlers can now be used to process RFIDICs much more quickly and inmuch greater numbers. Any incrementally increased costs that areincurred through the creation of the larger poles (e.g., gold bumps)necessary for this design are more than recovered in the costs savedthrough the increased speeds, efficiencies and throughputs of anyimplemented bulk handling type manufacturing processes. Of course, sincethe particular embodiment of an RFIDIC as depicted in FIGS. 3-5 has allof its poles on one side of the RFIDIC, it would be necessary for anyutilized bulk handling device or process for this RFIDIC design to atleast be able to orient the RFIDICs to be face up at some point in thehandling process before the antennae are attached, which step is not aproblem in many makes and models of bulk handlers and processors,further discussion of which are provided in greater detail below.

Turning now to FIGS. 6 and 7, another exemplary RFIDIC having analternative pole arrangement according to one embodiment of the presentinvention is illustrated in top plan and side elevation views. Similarto the foregoing embodiment, RFIDIC 151 is preferably accompanied by anattached substrate or backing (not shown), as will readily understood bythose skilled in the art. RFIDIC 151 comprises an arrangement of eightpoles of two different types, 153 and 154, which are preferably goldbump type poles, although other amounts and types of poles are alsopossible. Each of the four corner poles 153 are adapted to be attachedto one or more antenna leads, with such adaptations including theunderlying chip circuitry connected to the poles being configured suchthat radio signals can be received into and emitted from the RFIDICthrough these poles, as will be readily understood by those skilled inthe art. Conversely, each of the four side poles 154 are adapted to beattached to one or more power or ground leads, with such adaptationsincluding the underlying chip circuitry connected to the poles beingconfigured such that appropriate ground or power leads are processedwithin the RFIDIC from these poles, as will be readily understood bythose skilled in the art. For purposes of further discussion herein, itwill be assumed that each of the four side poles 154 is a ground pole.Other poles not shown here can include dummy or other use poles, and maybe located on the same surface as poles 153 and 154, or elsewhere on theRFIDIC 151.

As can be seen in FIG. 6, the four antenna poles 153 are all formed ator near each corner of RFIDIC 151, with each being of ordinary size andshape. Similarly, the four ground poles 154 are all formed at or nearthe midpoint of each edge of RFIDIC 151, again with each pole being ofordinary size and shape. Hence, according to this embodiment, oversizedor irregularly shaped gold bumps are entirely unnecessary. It can thusbee seen that the arrangement of antenna and ground poles 153 and 154 issubstantially symmetrical about at least one axis across the face ofRFIDIC 151, such as, for example, diagonal axis 155. Other potentialaxes of symmetry include the other diagonal axis, a central horizontalaxis and a central vertical axis. This arrangement of poles not onlyallows a ground lead to be attached in addition to one or more antennae,but is also instrumental in permitting at least four differentrotational orientations of the RFIDIC at the antenna and ground leadattachment stages. Basically, any orientation of the RFIDIC wherein anyof the four sides are aligned in a particular direction, such as along aguide rail or other simple orienting tool, will be a proper orientationfor attaching antennae and a ground lead.

Referring now to FIG. 8, the RFIDIC of FIG. 6 further comprisingantennae attached in one particular arrangement to form an RFID tagaccording to one embodiment of the present invention is illustrated intop plan view. RFID tag 150 comprises the RFIDIC 151 illustrated inFIGS. 6 and 7, but now has the contact ends of two antennae leads 160attached to two of the four corner poles 153, while the contact end of aground lead or wire 161 is attached at an opposing side pole 154. In aparticularly preferred embodiment, the ground lead or wire willeventually travel in its path along a substrate or other backingmaterial (not shown) and connect with one or both of antennae leads 160,such an arrangement and connection as will be readily understood bythose skilled in the art. In this illustrative example, it should benoted that the automated devices and methods used in the manufacturingprocess can be used to first align RFIDIC 151 such that one side of thechip is in a given location and direction, such as along a guide rail. Asubsequent attachment of opposing antennae leads 160 and ground lead 161in the exact position and formation as shown will then be successful solong as RFIDIC 151 is an a substantially correct location and has asubstantially correct rotational orientation, which can be any “squared”rotational orientation (i.e., 0, 90, 180 or 270 degrees from “normal”).The term “substantially” is used here because any slight variance from aperfect overall location and any slight rotation of RFIDIC 151 from anyof the four perfectly squared rotational orientations will result in aslightly skewed location and/or rotational orientation, whereby thenormal attachment of antenna leads 160 and ground lead 161 will stillresult in a fully operable and functional RFID tag. Such a substantiallycorrect location and rotational orientation can be readily had throughuse of some bulk parts handling systems, such that traditional pick andplace methodologies are not necessary. Other details and advantages thatmay also apply are substantially similar to those discussed in theforegoing embodiment of FIGS. 3-5.

Turning now to FIGS. 9 a and 9 b, yet another exemplary RFIDIC having analternative pole arrangement according to another embodiment of thepresent invention is illustrated in front and back perspective views.RFIDIC 201 may or may not be accompanied by a substrate or backing (notshown) on either side, similar to the foregoing embodiments. RFIDIC 201comprises two poles 202 and 203, which are at least partially exposedregardless of the existence of any substrate or backing, and which arelocated on opposing front and back sides of the RFIDIC. As in each ofthe foregoing examples, poles 202 and 203 are poles adapted to beattached to one or more antenna leads, with such adaptations includingthe underlying chip circuitry connected to the poles being configuredsuch that radio signals are to be received into and emitted from theRFIDIC through these poles, as will be readily understood by thoseskilled in the art.

As seen in FIGS. 9 a and 9 b, antenna poles 202 and 203 are bothpreferably centrally located along each respective side of RFIDIC 201,and each pole is preferably relatively large, although smaller poles arealso possible, depending in part upon design preference and the level ofprecision inherent to any handling and antennae attachment apparatuses.As in the foregoing examples, the arrangement of antenna poles 202 and203 is substantially symmetrical about at least one axis across theRFIDIC 201, such as, for example, diagonal axis 205. As will beappreciated, a substantial number of alternative axes of symmetry arealso possible in this embodiment, especially in the event that theRFIDIC and/or poles are circular in nature rather than rectangular orsquare. As will also be readily appreciated, the antenna attachmentprocess for this embodiment will be somewhat different than the antennaattachment process for the previous embodiment, as antennae must beattached to both the front and back sides of RFIDIC 201.

Again, while such a pole arrangement may require the creation of largerthan normal contacts, the arrangement of poles in this embodimentlikewise permits a virtually infinite number of possible rotationalorientations of the RFIDIC at the antenna attachment stage, such thatbulk feeders and handlers can be more readily implemented into themanufacturing process. In the typical instance of a simple RFID taghaving a two-connection looped type antenna and capable of regularoperation under either a normal or reversed attachment of the twoantenna leads, virtually all rotational orientations, as well as eitherone of a face-up or face-down orientation, of RFIDIC 201 will result inthe correct placement of antenna leads at the time such leads areattached to poles 202 and 203. Such a universally acceptance of eitherface-up or face-down and any rotational orientation is though to resultin an RFIDIC embodiment having maximum flexibility with respect to thetypes and models of bulk handlers, feeders and other devices that can beused.

With reference to FIG. 10, an exemplary chip arrangement used in themanufacture of RFID chips according to one embodiment of the presentinvention is illustrated in top plan view. In many manufacturingenvironments, lead-frame and lead-frame based technologies are onepopular technique for mass-producing chips and other electroniccomponents, and such techniques and methods are readily implemented inan RFID manufacturing context as well. In-process RFID chips 201, whichmay be similar to the finished RFIDIC 201 as illustrated in FIGS. 9 aand 9 b, are shown at one stage of a lead-frame based manufacturingprocess. These RFID chips 201 are connected to a common web or tie bar210 via individual leads 211, which can be severed as desired at anappropriately designated time or process step, as will be readilyunderstood by those skilled in the art. Other typical and inherent stepsand formations in a lead-frame based manufacturing process (not shown)are also contemplated by the present invention, and all such typicalsteps and formations not shown, as well as that which is illustrated,can also be used for the manufacture of other RFIDIC embodiments aswell, such as RFIDIC 101 and RFIDIC 151 described previously. Once anappropriate stage of the manufacturing process is reached, whereby eachindividual RFIDIC can be separated from the rest, bulk handlers andprocessors can then be optimally used to streamline the process.

Turning now to FIG. 11, an exemplary bulk-processing device formanufacturing RFID tags according to one embodiment of the presentinvention is illustrated in top perspective view. Mass parts handlingsystem 300 preferably comprises a centralized receptacle or bin 310adapted to hold bulk-processed products 301 to be processed, and alsotypically adapted to at least assist in the initiation of the processingof such bulk-processed products. Such a mass parts handling system canbe, for example, one of the various vibratory or rotary parts feedersmanufactured under the Syntron® brand by FMC Technologies, Inc. ofChicago, Ill. In one embodiment, A Syntron® Model EB-00 parts feederdrive can be used in conjunction with a Model 5.55W8-OT outside trackbowl, although other standard and custom designed combinations can alsobe used to achieve a desirable result.

As also illustrated, an upward spiraling track 311 preferably beginswithin or near an edge of bin 310, wherein the processing and forwardingof bulk-processed products 301 begins. During operation, suchbulk-processed products tend to be forced against a retaining wall oftrack 311 as they progress upward, such that some degree of separationand relatively single file alignment is typically obtained. Afterpassing upward along track 311, bulk-processed products 301 (e.g.,RFIDICs) eventually reach a preferably broadened final track section312, whereupon they then preferably pass under or through a counting ortracking mechanism associated with a control device 313. After passingsuch a mechanism, products 301 are then preferably directed onto aseparate processing belt or track 314, whereupon they are thentransported away from bulk processor 300 and toward the next step in themanufacturing process, which could be, for example, an antennaattachment step.

Such a belt or track 314 may incorporate one or more guides, walls orother additional aligning apparatuses (not shown) to further regulate asingle file, laterally aligned and spaced nature of the bulk-processedproducts as necessary, such manufacturing and processing techniques aswill be readily understood by those skilled in the art. As set forthpreviously, the orientation of such bulk-processed products can belargely irrelevant where such products have incorporated one of theunique pole arrangement and chip designs disclosed herein, such that anyrotational orientation is possible. Similarly, any face-up or face-downchip orientation will also be possible for some designs. If suchflexibility in face up or down orientation is not possible, as in thecase of RFIDICs 101 or 151, then the mass parts handler system cantypically be modified to correct for such an instance. For example, aguide, wall or rail (not shown) can be implemented to flip over anyupside chips as they pass, or, alternatively, such a guide or barriercan be used to divert improperly oriented chips back into the bin 300 asthey attempt to pass a certain point in the spiral path 311.

The level of precision and automation that can be avoided through theabandonment of common pick and place methods in favor of such a bulk ormass parts handler is considerable. For example, were the orientation ofa typical RFIDIC to matter at an antenna attachment step, then suchRFIDICs could not be quickly and efficiently separated from a formationas depicted in FIG. 10 and deposited quickly, albeit haphazardly, into amass parts handler bin 310. Instead, individualized care would berequired for each RFIDIC, so as not to disturb the known to be correctorientation of the chip. Conversely, RFIDICs designed according to oneor more of the exemplary embodiments provided herein can be subjected tothe processing of a mass parts handler 300 or similar device, and do notrequire the use of a relatively more expensive and time consuming pickand place apparatus. Accordingly, a substantial amount of cost per partcan be saved through the use of bulk processors and handlers, which useis made possible by a symmetrical or otherwise manipulatively usefulchip and pole design.

Turning now to FIG. 12, another exemplary bulk-processing device formanufacturing RFID chips according to another embodiment of the presentinvention is illustrated in side cross-sectional view. Bulk processingsystem 400 is specifically designed for use with RFIDICs having poles onopposing sides, such as RFIDIC 201 as illustrated in FIGS. 9 a and 9 b.Bulk hopper or feeder 410 is a repository for individually separatedRFIDICs 401 to be processed en mass. Again, such individual RFIDICs 401can be separated and processed quickly in this manner, with orientationbeing irrelevant for the most part due to the symmetrical design of eachchip and its poles. Each RFIDIC 401 is processed along or through achute or other outlet of hopper 410, either randomly or via someadditional automated means, as desired. For example, the outlet chutemight be relatively full of product to be processed, but an automatedgate at the end can be programmed to regulate the amount and speed atwhich product is ultimately released.

Upon release, each RFIDIC 401 slides or is otherwise placed onto acontinuously moving sheet of substrate 420, into which antennae tracesand leads may already be built. Similarly, a second continuously movingsheet of substrate 430 is provided, into which antennae traces and leadsmay also be already built. Such antenna substrate sheets 420 and 430 canoriginate from a roll or other source of material, as desired, and arepreferably pulled along by a plurality of rollers such as rollers 421,422 and 431, with additional rollers and/or guides in the process alsobeing possible both before and after that which is illustrated. Aftertraveling along for some length at a given location on substrate sheet420, a particular RFIDIC 401 will encounter substrate sheet 430, whichis directed over the top of the RFIDIC. At such a “sandwiching” of theRFIDIC between two antenna substrate sheets, the entire device passesthrough rollers 422 and 431.

Although such rollers can be used in part to guide the continuous sheetsof antenna substrate, rollers 422 and 431 can also serve the dualpurpose of press attaching the antennae to each RFIDIC 401. Theresulting continuous RFID tag “sandwich” 440 that exits the rollers canthen be cut or otherwise separated appropriately at some later processstep (not shown). As will be readily appreciated, both continuoussubstrate sheets may have repeating antenna traces and patterns built into the sheets, such that each RFIDIC can be ideally located at a centralpoint on each pattern, and such that the cutting or separating ofextruding product later can be more easily accomplished in a regulatedpattern in order to form the final individual RIFD tags.

Although the foregoing invention has been described in detail by way ofillustration and example for purposes of clarity and understanding, itwill be recognized that the above described invention may be embodied innumerous other specific variations and embodiments without departingfrom the spirit or essential characteristics of the invention. Certainchanges and modifications may be practiced, and it is understood thatthe invention is not to be limited by the foregoing details, but ratheris to be defined by the scope of the appended claims.

What is claimed is:
 1. A method of manufacturing a radio frequencyidentification tag, comprising: providing a first radio frequencyidentification integrated circuit having an interconnect system formedon said radio frequency identification integrated circuit; and utilizinga parts handling system to attach an antenna to the interconnect systemof said first radio frequency identification integrated circuit, whereinsaid interconnect system is arranged such that said at least one antennacan be coupled to said interconnect system whenever the rotationalorientation of said radio frequency identification integrated circuit isat any of a plurality of distinct positions with respect to said atleast one antenna and wherein said parts handling system attaches saidantenna to said radio frequency identification integrated circuitwithout controlling for the rotational orientation of said radiofrequency identification integrated circuit.
 2. The method of claim 1,wherein said utilizing step comprises utilizing a mass parts handlingsystem having a rotary feeder drive.
 3. The method of claim 2, whereinutilizing step further comprises utilizing an outside track bowl.
 4. Themethod of claim 1, wherein said interconnect system is arranged suchthat said at least one antenna can be coupled to said interconnectsystem regardless of whether said radio frequency identificationintegrated circuit is either face-up or face-down.
 5. The method ofclaim 1, wherein said interconnect system comprises two poles, whereinsaid the arrangement of said poles is substantially symmetrical about atleast one axis along said radio frequency identification integratedcircuit.
 6. The method of claim 1, further comprising the step ofcoupling at least one ground lead to said interconnect system.